Method of fitting an orthopedic article of footwear



Dec. 22, 1959 w. M. scHoLL METHOD OF FITTING AN ORTHOPEDIC ARTICLE OF FOOTWEAR Filed NOV. 13, 1957 5 Sheets-Sheet 1 Dec. 22, 1959 w. M. scHoLL 2,917,757

METHOD OF FITTING AN ORTHOPEDIC ARTICLE OF FOOTWEAR Filed Nov. 13, 1957 3 sheets-sheet 2 megwflfllii/,

EZZZQF mz/,M /17 60s/au M Mem WW2 Eff@ IEE Dec. 22, 1959 W. M. scHoLl. 2,917,757

METHOD OF FITTING AN ORTHOPEDIC ARTICLE OF FOOTWEAR Filed Nov. 13. 1957 3 Sheets-Sheet 5 Erg. 9

/ z i /f f 251 Zay-liar A//a/A/l/ M 35A/0u fifi@ Unite ll/[ETHD F FITTING AN ORTHOPEDIC ARTICLE 0F FOOTWEAR This invention relates to improvements in an orthopedic article of footwear and to a method of fitting the same, the invention being highly desirable for use by a chiropodist or other foot specialist in the comfortable and proper fitting of afflicted, deformed, partially amputated feet and the like, the article of footwear individually fitted to a particular foot by the specialist at the time of purchase, although the invention may have other uses and purposes as will be apparent to one skilled in the art.

In the past, where a patient had a deformed, aficted, or partially amputated foot, it was customary to have shoes made to order or specially built to acquire a proper fit of the particular foot. Such, of course, was a highly and sometimes prohibitively expensive procedure, frequently resulting in a patient utilizing a more economical pair of footwear, suffering discomfort, aggravating the aiiction, or causing the patient to walk in an awkward and unnatural manner. ln most cases, where specially designed shoes were utilized, it was necessary, to make a complete cast of the patients foot, and then form a last from that cast and build the shoe around that last. In no instance of which I am aware was there a way of taking an impression of the foot and immediately properly fitting a shoe, sandal, or the like to that foot from the impression so taken.

With the foregoing in mind, it is an important object of the instant invention to provide a shoe or the like including an extra thick and removable insert or inlay made of material that may be readily carved, fashioned, or Sculptured to intimately lit an individual foot.

Another object of the invention is the provision of a shoe or the like having an extra thick removable insert with relatively high bounding7 edges, whereby the insert itself may be utilized as a molding pan to take an irnpression of a particular foot in some suitable moldable material.

Also, an object of this invention is the provision of a shoe having an upper built eXtra high to accommodate an extra thick removable insert, which insert may itself be used as a means of taking an impression of a particular foot, and then replaced in the shoe after having impression material added thereto in the proper location and proportion.

A further feature of the instant invention resides in the provision of an orthopedic shoe or the like in which the upper is made extra high to accommodate an extra thick insert that may be shaped to an individual foot, the upper being lower at the top on the outer side than on the inner side, to better accommodate the outer ankle bone.

Still a further feature of the instant invention is the provision of an orthopedic shoe having a removable part, which part may be reshaped and intimately fitted to an individual foot by a skilled operator at the time the shoe is purchased, and then replaced.

Still another object of the instant invention is the provision of a new and novel method of fitting a shoe` States Patent O to an individual foot, substantially regardless of the condition of the particular foot, and without detracting from the appearance of the shoe itself.

It is also an object of this invention to provide a method of fitting a shoe having a removable part to an individual foot, consisting of removing the part, applying a moldable compound to it, taking an impression of the foot, allowing the compound to set, and then carving or sculpturing the set compound, or both the compound and 0 part, and rejoining the part with the shoe.

Still a further feature of the instant invention resides in the provision of a method of fitting a shoe to a particular deformed or aficted foot, comprising removing an insert from the shoe, and utilizing that insert as a molding pan to take an impression of the foot in a compound applied directly to the insert, and thereafter carving the set compound or both the compound and the insert to t the particular foot, and replacing the insert in the shoe.

While some of the more salient features, characteristics and advantages of the instant invention have been above pointed out, others will become apparent from the following disclosures, taken in conjunction with the accompanying drawings, in which Fig. 1 is a side elevation of a shoe embodying principles of the instant invention;

Fig. 2 is an enlarged transverse vertical sectional view, taken substantially as indicated by the line II-Il of Fig. l, looking in the direction of the arrows;

Fig. 3 is also a transverse vertical sectional view, taken substantially as indicated by the line III-III of Fig. l;

Fig. 4 is a fragmentary diagrammatic view illustrating a possible preliminary treatmentof the insert or inlay removed from the shoe, prior to the taking of a foot impression;

Fig. 5 is a longitudinal vertical sectional view, taken substantially centrally through the removed inlay or insert, showing the same provided with material for the taking of an impression of the foot;

Fig. 6 is a fragmentary vertical sectional View taken longitudinally of the removed insert or inlay and indicating the manner in which the impression of the foot may be taken;

Fig. 7 is a longitudinal vertical section through the completed insert or inlay after it has been conformed to the patients foot;

Fig. 8 is a top plan view of the structure of Fig. 7; and

Fig. 9 is a transverse vertical sectional view taken substantially as indicated by the line IX-IX of Fig. 8, looking in the direction of the arrows.

As shown on the drawings:

The illustrated embodiment of the instant invention is a shoe or similar article of footwear, particularly designed for sale by a chiropodist or other'foot specialist, and the shoe is intimately fitted to a particular foot contemporaneously with the purchase of the shoe. The shoe is not designed for general sale in a shoe store, but is one that may be altered contemporaneously with the purchase thereof by a skilled operator, such as a chiropodist or foot specialist, whereby the purchaser has a proper fit regardless of the affliction or deformity `of his particular foot, and need not go to the expense and delay of having a specially built pair of shoes made for him.

The shoe itself has the appearance of an ordinary dress shoe of thev conventional type, but there is sufficient difference in the construction of the shoe to permit theindividual fitting of the shoe to a particular foot. After the shoe has been properly tted toan individual foot, the wearer may use it without embarrassment, since it would require expert inspection to determine that the shoe was specially fitted and orthopedic in character.

Conditions for which the instant invention is indicated include the following: foot strain, hallux valgus, enlarged sesamoids, dropped metatarsal heads, arthritic or enlarged joints, tailors bunion, longitudinal arch weak- -ness, icorns, callouses, excrescences on plantar surface,

iheelfspur, forefoot and metatarsal imbalances, pes cavus,

leg shortage, partial amputations, etc.

The illustrated embodiment of the instant invention is a shoe ofthe low-cut or oxfordtype, and comprises a laminated outer sole made of any'suitable material, but ine-the illustrated instance, the outersole consists of a bot- `tom'tap 1 which may be crepe-rubber or the like, an ele- 'va-ting tap Z inthe rear portion to elevate the heel, and

which may be of sponge rubber or other suitable material, and aninner or upper tap 3 of solid sheet rubber, leather, or the like. `A welt 4 may be secured to the VVouter'sole bystitching in a known manner, and this welt Fis'lalsostitched toa structural insole-5 disposed over the usual'filler 6. An upper 7 is secured in position by the same'seam'that joins the welt with the structural insole. vOutside ofra change in the upper to be later described,

'th'eishoe so far described is of known construction, and

theappearance of a commonly seen shoe to the ordinary observer. It should also be noted that in order to better fit the foot, and particularly to accommodate the outer `ankle bone of the user in a comfortable manner, the higher upper is cut lower at the top on the outer side of the ankle region than on the inner side, as indicated byV numeral '10. By way ofexample, the upper may be 3A; of an inch lower on the outer side than on the inner side, so that the outer ankle vbone may freely extend over the upper without discomfort.

In order to acquire a properly sized upper to accommodate the extra thick inlay 8, the shoe is preferably lasted around the inlay during its construction. In other words, the inlay is initially made a part of the last, in effect, and the shoe built entirely around it.

The inlay 8 may be made of any suitable material that ycan readily be carved, Sculptured, or otherwise fashioned by the use of easily manipulatable abrasive or cutting tools. One satisfactory substance for the inlay is cork, and the inlay may be made of compressed ground Vcork and cement, latex, plastic, or equivalent material lpreferably molded in one piece.

As initially provided with the shoe, the inlay includes a thick body portion 11, and this body portion may or may not be provided with a denser under layer 12, which is, of course, much thinner than the body portion 11 of tively high bounding edge entirely therearound, kas indicated at 13. This enables the inlay to be used as a mold pan when an impression is taken of the foot. Prior to utilizing the inlay as a mold pan, it is preferable to cement a sheet of aluminum foil or equivalent material 14 vto the upper surface of the inlay, such sheet being smooth so as to precisely follow the contours in the upper face `of the inlay. This sheet functions as a non-absorbent base-for a moldable substance or compound 15, which 4when-set,firmly attaches itself to the surface of the sheet l14 v'In `Figs. 2and 3,'v a finished or fitted insert Lor inlay is =.illustrated, andit will.be-seenthattheinlay contains a quantity ofset Vor hardened compound 15 in keeping with the particular foot to which the device was fitted. After a proper fit is established, it is preferable to provide a thin smooth cover layer 16 of light leather, monks cloth, or other equivalent material which may be cemented to the shaped inlay, and is preferably intimately fitted so that it accurately follows all the contours on the upper face of the inlay. f

As stated above, the insert or inlay 8 is not cemented or otherwise secured within the shoe, as it is provided with the shoe initially, and it is not necessary to cement or secure that inlay within the shoe after it has been provided with the compound i5 and otherwise shaped for intimately fitting a particular foot. It is sufiicient to merely place the completed inlay in the shoe, because it fits the shoe so finely by virtue of the shoe being lasted therearound, that it will not change shape or position during use. This provides the advantage of being able to remove the inlay from the shoe at any time desired, and thus effect a reshaping of the inlay as may be desired iffthe foot affliction is improving by virtue of use of the inlay.

While the method of 'providing an inlay or insert to fit a particular foot may vary through a wide range of individual steps and stillnot depart from the principles of this invention, a satisfactory and usually preferred course ot' procedure will be specically defined herein. It willrbe apparent to one skilled in the art that certain steps Yherein described will not always be necessary, and in certain instances additional steps might be required, the entire procedure being dependent to a resonable eX- tent in regard to specific operations indicated by the individual foot being fitted.

For purposes of convenience, the fitting of an inlay to a particular footwill be described in connection herein with a single foot, it being understood that the same general course of procedure would be followed in connection with the other foot.

-Theparticular inlay is first removed from the article of footwear, and the patients bare foot is placed on that inlay to make certain that the size and width of the inlay lare correct. The inlay may then be marked with chalk or equivalent material to denote points where allowance is`to be made for bony prominences on the foot, such as enlarged sesamoids, tailors bunion, dropped metatarsal heads, hallux valgus, hammer toes, etc., and for other afiiictions where pressure elimination is required.

Now if any such marks were made on the inlay, pockets may then be ground out of the inlay at the points marked, as seen in Fig. 4, by utilizing a suitable burr 17 carried on the end of an office drillV f8, or with other equivalent apparatus. The device may beheld in the hand of the operator as shown, during this operation, and should the cut away portion 19 be larger than originally intended, the molding compound to be later described will fillit in so that ultimately the prominence or other affiiction of the foot will be properly fitted. In Fig. 4, I have illustrated the inlay as comprising only one piece `11, without the aforesaid denser under layer 12, merely to indicate that that particular under layer is not necessary unless it is desired for some purpose.

Now with reference to Fig. 5, it will be seen that after a recess such as 19, or more of them, is ground in the inlay, the aforesaid sheet of aluminum foil or equivalent material is preferably cemented to the upper surface of the inlay and formed intimately thereto by the fingers of the operator. This sheet 14 may be trimmed with scissors or the like to allow an overlap 20 entirely around the inlay, and a satisfactory length for this overlap is approximately 1/2 inch. As shown in Fig. 5, theoverlap is preferably pressed down tight against the bounding edge of the inlay.

The molding compound is then prepared and this may satisfactorily be a mixture of cork flour or ground cork, Wood tlouror-finesawdust, and ground rubber, although other mixtures as will be apparent to one skilled in the art might equally as well be used. This mixture is then mixed in any suitable vessel with a quantity of liquid latex or equivalent material until the compound has a relatively stiff but spreadable consistency, substantially that of peanut butter. Using a spatula or equivalent tool, the mixed compound is then applied to the inlay on top of the sheet14 to provide the aforesaid applied compound 15. In applying the mixed compound, it is preferable to apply a little at a time, smoothing it away from the center so that the outside edge13 of the inlay acts as a scraper. Usually 3/16 of an inchV is sufficient for the forward part of the inlay, and a thickness of approximately l/s inch for the heel and arch part, but such thicknesses may obviously be varied to suit the requirements of the particular foot. Corrections may be built up by adding more of the compound at specific locations, and it is well to apply a little extra compound at the point coinciding with the ridge of the metatarsophalangeal joints.

Next, the soft but` spread compound is preferably covered with a relatively thin and impervious plastic iilm or sheet as indicated at 21 in Fig. 6, leaving ample overlap as indicated at 22. The inlay is next placed upon the floor, with the heel portion thereof resting upon a temporary heel block 23, and with the patient seated and the leg perpendicular to the floor, the foot is carefully placed on the inlay in the position the foot will assume in the finished article of footwear, as indicated in Fig. 6, the foot being indicated at 24. After making sure that the heel is in correct position, pressure is exerted downwardly on the patients knee to seat the heel of the foot in the heel cup of the inlay. The patient is then assisted to a stand ing position, keeping the weight mostly on the other foot, and the patient is then caused to simulate a walking step by exing his knees, without raising the heel of the foot under treatment from the inlay. Now with the patient standing upright, pressure is exerted firmly in a downward direction on the toes and forepart of the foot so as to properly position each toe on the inlay.

With the patient reseated, and the foot still on the inlay, inspection may be made to determine that the inlay properly conforms to the foot, and any smoothing-out adjustments that may appear necessary may then be made, with particular regard to the distal ends of the toes, so as to permit the toes to elongate. The foot may then be removed, the sheet 22 elevated, and a spatula run around the edge of the inlay to trim off the excess mold compound.

The inlay for the other foot may then be prepared in similar manner, and after both molds or inlays are made, the sheets 22 are carefully removed and the inlays put aside to dry.

After approximately 24 hours, the molds will have dried to quite an extent, but will still be pliable, and when the patient returns, substantially 24 hours after the first visit, the marginal portion 20 of the foil sheet is trimmed off so that the sheet is ush with the edge 13 of the inlay as seen in Fig. 7. The two molds may then be covered with a sheet 22, placed in a pair of shoes or the like, and the patient may Walk around with them in use for fifteen to twenty minutes, to create perfectly balanced molds. At this time, if necessary, the sheets 22 may be removed and minor adjustments made to each mold.

When the molds lit the feet exactly, the sheets 22 are removed, and the cover 16 cemented over the upper face of each mold. After this cement, which is preferably quick-drying, has set, the cover 16 may be trimmed to be flush with the upper edge of the inlay. The inlays may then be placed back in the shoes, and the patient may walk in them for a time to make the cover 16' conform precisely to the contours and indentations of the mold.

The molds may be then put aside for complete hardening, and should then be ready for continuous use, although some operators may prefer a further inspection. It should also be noted that some specialists may apply the cover 16 immediately rather than utilize the sheet 22, but such does not give the freedom of adjusting `the mold or `inlay during its preparation, as the processdescribed above does.

Of course, when the mold is placed within the shoe or other article of footwear, the temporary heel block 23 is eliminated.

Now looking at Figs. 8 and 9, I have illustrated a com pleted mold which allows for dropped first and fth metatarsal `heads and also for an amputation of the fourth and fth toes. With reference particularly toV Fig. 9, it will be noted that the compound 15 is elevated as at 25 in front of the fourth and fifth toe stubs. f

In the case of a sandal or similar article of footwear,` the inlay 11 is preferably built into the sandal as a part thereof. Accordingly, it is then preferable to turn backthe straps of the sandal and buckle them underneath the outer sole, if possbile, or in some other manner retain them turned away from the inlay so that the same is free to function as a mold pan. The same general operation of conforming each inlay to the foot of the wearer is followed as above described, with the exception that the foil layer is preferably eliminated, and the mold compound is applied directly to the upper face of the inlay 11. Also, during .the initial impression into the soft mold compound, the straps are preferably buckled around the patients foot.

With the instant invention it will be especially noted that if the patient does not have a permanent disability or deformity of the foot, but does have an aliiiction that will respond to treatment and gradually improve, the inlay may be adjusted to compensate forthe improvement at substantially any desired time. More mold compound may be added and fashioned to the insole Vto compensate for a reduction in size of the atiiiction, and various other adjustments made so that as the afiiiction improves, it is not necessary to purchase new artices of footwear periodically, but the first pair may be utilized until they are worn out.

From the foregoing, it is apparent that I have provided an orthopedic article of footwear that is extremely economical in comparison with shoes made to order for special purposes, and which may be readily and easily fitted to any particular individual foot substantially regardless of the condition of the foot, and which gives the appearance of the commonly seen dress shoe when worn. Obviously, the instant invention enables the patient to walk in as close to a natural manner as possible, and at the same time provides the comfort and benefit of a correct fitting article of footwear. It will also be noted that I have provided a new and novel method which can very facilely and economically be employed to properly tit the article of footwear to any individual foot.

It will be understood that modifications and variaions may be effected without departing from the scope of the novel concepts of the present invention.

I claim as my invention:

l. The method of fitting an orthopedic article of footwear having a removable inlay therein to an individual foot, including the steps of using the inlay as a moding pan for moldable compound, taking an impression of the foot in the compound, and allowing the compound to harden, and replacing the inlay with the compound in the article of footwear.

2. The method of fitting an orthopedic article of footwear having` a removable inlay to an in.d.vidual foot, including the steps of using the inlay as a molding pan for a moldable compound, taking an impression of the foot in the compound, allowing the compound to set, and contemporaneously carving the compound to better shape the same and remo've the excess, and replacing the inlay with the compound in the article of footwear.

3. The method of iitting an orthopedic article of footwear having a removable inlay to an individual foot, including the steps of using the inlay as a molding pan for a moldable compound, taking an impression of the foot in the compound, allowing the compound to set, carving the compound to better fit the particular foot, adding compoundrwhere needed, and retting the shaped inay to the foot, and replacing the inlay with the compound in the article'of footwear.

4, The method of fitting an orthopedic shoe having a removable insert to an afflicted foot, including the steps of'removing the insert, fitting it to the particular foot, and carving the insert to intimately fit the aiicted foot, and replacing the inlay with the compound in the article of footwear.

5. The method of tting an orthopedic shoe having a removable inlay to an afflicted foot, including the steps of removing the inlay, tting it to the particular foot, carving the inlay, adding a moldable compound to the inlay to build up the same where needed, allowing the compound to set, and replacing the inlay in the shoe.

6. The method of fitting a shoe having a loose and relatively thick inlay to an individual foot, including the steps of removing the inlay, using the inlay as a molding pan' for a moldable compound, taking an impression of the foot in the compound, allowing the compound to set, carving both the compound and the inlay to cause the inlay to intimately fit the particular foot, and replacing the inlay in the shoe.

7. The method of fitting a shoeto a particularfoot, including the steps of removing a part of `the shoe, utilizimg said part as a mold pan to take an impression of the foot in a moldable compound applied to' said part, allowing the compoundV to set and adhere to said part, then carving the compound, and replacing said part'loosely in` the shoe.

8. The method of fitting a shoe to-a particular foot, including the steps of removing a part-of the shoe, utilizing said part as a mold pan to take an impression of the foot in a moldable compound applied to said part, allowing the compound to set and adhere to said part, then sculpturing both the set compound and part to intimately fit the particular foot, and replacing said part of. the shoe.

9. The method of tting a particular foot with an orthopedic article of footwear having an inlay with a high bounding edge to underlie the plantar surface of the foot, including the steps of placing the particular foot on the naked inlay, grinding cavities in the inlay itself il necessitated by the particular foot, filling the inlay with moldable compound, taking an impression of the particular Vfoot in said compound, allowing the compound to partially harden, iitting the particular foot to the compound, carving the compound if required, allowing the compound to fully harden, and replacing the inlay and hardened compound in the article of footwear.

References Cited in the le of this patent UNlTED STATES PATENTS 2,008,207 Greenberg July 16, 1935 2,092,910 Daniels Sept; 1`4, 1937 2,417,852 Zerkle Mar. 25, 1947 2,589,241 Galhouse Mar. 18, 1952 2,742,657 Sloane Apr. 24, 1.956 2,794,270 Dubner June 4', 1957 

